http://psc.tamu.eduhttp://psc.tamu.edu

CONTINUING EDUCATION

2014-2015 COURSE GUIDE

Mary Kay O’Connor

PROCESS SAFETY

CENTER

MAKING SAFETY SECOND NATUREMAKING SAFETY SECOND NATURE

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Mission Lead the integration of process safety – through education, research, and service – into learning and practice of all individuals and organizations.

Vision

Serve as the Process Safety Center of Excellence that promotes:

Process safety as a personal value that is second nature for all stakeholders

Continuous progress toward zero injuries and elimination of adverse impacts on the community.

Values

Health and safety of the community and the workforce

Sharing of knowledge and information

Sound scholarship and academic freedom

Diversity of thought and viewpoint

Independence to practice sound science

Integrity of science validated by peer review

Freedom to evaluate and comment on public policy

Progress without undue influence by special interests

Individual and group achievement

MARY KAY O’CONNOR PROCESS SAFETY CENTER

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Courses Offered via Distance Learning………………………………………………………………………..

Courses Available Upon Request (Course descriptions in Cumulative Course Guide)

Registration…………………………………………………………………………………………………………………….

Course Number Title Page Number

Continuing Education Program…………………………………………………………………………………….

Continuing Education (CE) Course Descriptions

Process Safety Management—Fundamentals…………………………………………………….

What Went Wrong? Learning from Chemical Plant Incidents (one-day)...…………..

Layer of Protection Analysis (LOPA)…………………………………………………………………….

Process Hazard Analysis Leadership Training……………………………………………………...

Safety Instrumented Systems (SIS) Implementation…………………………………………...

Safety Integrity Level (SIL) Verification………………………………………………………………..

Pressure Relief Systems—Best Practices…………………………………………………………...

Reactive Chemical Hazards Assessment (one-day)…………………………………………….

Reducing Human Error in Process Safety (one-day)....……………………………………….

Disposal Systems Analysis—Best Practices…………………………………………………………

Engineering Decision Making (one-day)...………………………………………………………….

Gas Explosion Hazards on Offshore Facilities……………………………………………………..

1082

1141

2042

2052

2073

2082

3102

3111

3121

3151

4061

4072

TABLE OF CONTENTS

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Expertise

Customized Courses

Symposia

Each year the Center hosts a Fall Symposium and a Spring Symposium. Both events are eligible for continuing education credit and offer a variety of training and educational opportunities. Please visit our website at: http://psc.tamu.edu/symposia for event information.

CONTINUING EDUACTION PROGRAM

Safety Practice Certificate

The Safety Practice Certificate is a program which allows engineers currently in industry to gain a greater knowledge of process safety. This program was created for those industry engineers who want a more in-depth study of process safety in chemical engineering.

The certificate requires 125 PDHs for completion within a three year timeframe. The certificate has 84 PDHs of required courses. The remaining hours may be obtained through courses offered at training facilities in Houston, TX, other distance learning course offerings, and through the Center’s International Annual Symposium in College Station, Texas. There is some flexibility in topic choice with the CE classes, so that applicants can focus their studies in a specific topic area.

The application for this certificate is always open. A worksheet to help you keep track of your credits earned and the application for the program are available at http://psc.tamu.edu/education/safety-practice-certificate. Upon completion of the program requirements, participants will be issued a certificate of completion.

Instructors include leaders in the fields of process safety management, liquefied gas safety, ammonia and fertilizer plant safety, refinery and chemical plant safety engineering, and risk assessment for the process industries.

The Mary Kay O’Connor Process Safety Center also provides structured training programs aimed at specific company objectives. Any of our short courses can be tailored to the specific needs of the facility if desired. Having the instructor travel to your facility eliminates travel time and costs for the facility employees. This option presents a win-win for you and your employees—no travel, tailored course, and a focused group of colleagues with similar experience and objectives. These courses can accommodate audiences as small as 8 or up to 20, in general. For more information and contract arrangements for a customized course, please contact Valerie Green at 979-845-6884 or by email at val-green@tamu.edu.

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Continuing Education Units (CEUs)/ Professional Development Hours (PDHs)

The CEU is a nationally recognized unit designed to provide a record of an individual’s continuing education achievements. The Engineering Program Office of Continuing Education, in cooperation with the Texas Engineering Experiment Station, has approved the Mary Kay O’Connor Process Safety Center short courses for CEUs.

Per the Texas Board of Professional Engineers: Each license holder shall meet the Continuing Education Program (CEP) requirements for professional development as a condition for license renewal. Every license holder is required to obtain 15 PDH units (1.5 CEUs) during the renewal period year. A minimum of 1 PDH (0.1 CEU) per renewal period must be in the area of professional ethics, roles and responsibilities of professional engineering, or review of the Texas Engineering Practice Act and Board Rules. The complete rule can be found on the Texas Board of Professional Engineers website at RULE § 137.17 Continuing Education Programs.

A CEU certificate will be issued by the Engineering Program Office of Continuing Education upon the successful completion of each course.

PARTICIPANT COMMENTS

“The SIS class tied the code back to practical application.”

……………………………………………………………………………………………Mason D. Martin, ConocoPhillips

“Reviewed the actual step-by-step process for LOPA.”

…………………………………………………………………………………………Stephen Greco, Lubrizol-Deer Park

“I enjoyed the methodology for evaluating chemical hazards.”

…………….………………………………………………………………………Ronnie Hampton, Eastman Chemical

“I enjoyed the identification of terms and conditions of PSM/RMP.”

……………………………………………………………………………………………….…William (Bill) Worley, El Paso

“Pressure relief design from the equipment perspective.”

………………………………………………………………………………………………Charles Chan, Sempra Utilities

“The instructor had the ability to present the SIS material in an understandable manner with real-world examples.”……………………………………………………Tom Rutherford, Pegasus Intl.

“All PSM points were very helpful and I look forward to taking the advanced class.”

………………………………………………………………………………………………………………John Jewett, El Paso

“Presentation of Inherent Design was excellent. Delivery and slides were informative, yet not too detailed.”…………………………………………………………………………..…………Brad Cozart, DNV

“Thanks again for a well-presented and informative course. This was the second course I’ve taken at MKOPSC and both have been top notch.”

…………………………………………………………………………………………..Jesse L. Roberts, BHP Petroleum

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1082 Process Safety Management—Fundamentals

2-Day Course

Program Content:

This short course is designed to teach and apply the fundamentals of chemical process safety.

Objectives:

To provide a basic understanding of Process Safety and the requirements of OSHA PSM Regulation 29 CFR 1910.119 and EPA Risk Management Plan 40 CFR Part 68.

To understand through case studies how the failure of Process Safety management elements were found to be the root cause of major incidents in the petroleum industry.

To provide information on how to implement, monitor, and audit a Process Safety Management program.

To illustrate through exercises the identification of hazards and the ranking of risks.

Day 1:

Module 1: Introduction

Course administration

Course participants

Objectives of the course

History of Process Safety legislation in the USA illustrated through past events

What is Process Safety?

Process Safety concepts and overview of the PSM elements

Module 2: Process Safety Management Elements (Description of Each Element)

Documentation

Employee Participation

Accountability and Leadership

Process Safety Information

Process Hazard Analysis

Mechanical Integrity; Case Study: “Humber Refinery—Catastrophic Failure of De-Ethanizer Overhead Pipe”

Safe Work Practices (Hot Work); Case Study: “Piper Alpha Disaster”

Contractor Management

Operating Procedures; Case Study: “Feyzin LPG Disaster”

Training and Competence

Management of Change; Case Study: “Flixborough Disaster”

Pre-Startup Safety Review

Emergency Planning and Response; Case Study: “Major Tank Fire”

Incident Investigation

Process Safety Audit

Trade Secrets

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1082 Process Safety Management—Fundamentals (cont.)

2-Day Course

Day 2:

Module 3: Life Cycle Model

Holistic Approach

Inherent Safety

Project Management and Process Safety

Getting it “Right”

Module 4: Hazards and Consequences

Types of Failures releasing hazardous materials

Video Session documenting vapor cloud, flash fire, explosion (deflagration and detonation), pool fire, BLEVE, Boil-over

Toxic Releases

Facility Siting

Module 5: Risk and Risk Analysis Methodologies

Hazard and Risk

Types of Risk

HAZOPS Study

Task Risk Assessment—Exercise

Module 6: Human Factors

A Just Safety Culture

Ergonomics, fundamental behavior, human error

Module 7: Texas City Disaster

Presentation/Video

Exercise: Draw out the holes in the protective barriers using the Swiss Cheese Model

Module 8: PSM and Other Management Systems

Using Synergy from Other Management Systems (ISO 9001, 14001 & OSHA 18001)

TQM (Total Quality Management)

Gap Analysis

Key Process Safety Indicators

Audits

Module 9: Course Summary Followed by an Open Quiz

Who Should Attend?

Anyone involved in improving process safety; including chemical engineers, mechanical engineers, safety and health personnel, industrial hygiene personnel, and operators, and maintenance supervisors. 1.4

CEUs

14

PDHs

8

1141 What Went Wrong? Learning from Chemical Plant Incidents

1-Day Course

Program Content:

Awareness of chemical and petroleum process safety fundamentals is vital to the success of all that work in chemical plants and refineries. Get a real life look at case histories of process accidents in the chemical industry. Heighten your awareness, understanding, and appreciation of the fundamentals which create chemical plant accidents. Participate in an interactive review and exchange covering numerous actual process incidents reinforced by hundreds of vivid images of plant sites in peril, fires, or damaged equipment. These exercises examine the management system needs for safe operations.

Enjoy a practical, fast-paced, interactive exchange on process safety details between you, other attendees, and the presenter.

Improve safety awareness within facilities when employees have failed to notice the high potential for safety related incidents.

Increase awareness level of proper Management of Change policies.

Understand the basics of fires and explosions and understand “Tales Tanks Tell” about process safety (Tanks are often the victims of chemical process and reveal mistakes), as illustrated through case histories.

Understand the fundamentals of process safety to protect people, ensure the integrity of the equipment, and preserve the viability of the organization.

Gain an appreciation of a “situation response” teaching technique that the attendee can use in their own companies to spread knowledge and understand some of the basics of human error.

Learn of resources to use at your workplace while witnessing fires, explosions, or damaged equipment, and determine the approach to shape your process safety programs.

Course Outline:

Introductions & expectations

Risk & Perceptions of Risk—Risks are not always as they appear. This introductory module examines risks of industry and ordinary life factors.

Accidental Fires & Explosions—This module looks at the fundamentals of fires and explosions. It also reviews cases of incomplete hot work permits and process maintenance flaws which lead to massive leaks.

Plant Modifications: Troubles & Treatment—This portion of the program looks at how many small, seemingly helpful, well-intentioned changes can lead to unintended troublesome consequences. This reinforces the need for effective Management of Change programs.

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1141

0.7

CEUs

7

PDHs

What Went Wrong? Learning from Chemical Plant Incidents (Cont.)

1-Day Course

Incident Investigations—How Far Should We Go? This is a classic look at accident investigations developed by Dr. Trevor A. Kletz, in which five different investigators reviewed the same case and came up with five drastically different causes.

Pump Explosions—Dangers of dead heading pumps.

Tales Tanks Tell—A look at a wide array of process safety incidents in which various elements of process safety were not considered and tanks suffered.

Human Error—Why some people act as they do within chemical plants.

Layers of Protection—A look at many of the within-the-fence training, hardware, and procedures with enhanced process safety

Wrap Up, Evaluations, and Quiz

The majority of incidents discussed are well-documented in Roy Sander’s Book (2005) Chemical Process Safety—Learning from Case Histories. Third Edition (ISBN 0-7506-7749-X).

Who Should Attend?

Chemical Process Safety must be second nature to all who design, operate, and maintain refineries and chemical plants. The material is best suited to operations supervisors, lead operators of chemical manufacturing units or petroleum refining units, maintenance foremen, plant related managers, process engineers, design engineers, plant safety engineers, property insurance professionals, and other professionals interested in Chemical Process Safety awareness.

Note: This class is also available as a two-day class.

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2042 Layer of Protection Analysis (LOPA)

2-Day Course

Program Content:

Layers of Protection Analysis (LOPA) is a popular risk analysis technique. It is conducted after a process hazards analysis has identified hazardous events needing further analysis to better understand the functional and risk reduction requirements for the safeguards. This course discusses the quantitative assessment of initiating event frequencies and the robustness of safeguards.

The course stresses understanding of event propagation, the attributes required for safeguards to be qualified as Independent Protection Layers (IPL), and the proper determination of hazardous event frequencies. Evaluating enabling conditions and the appropriate use of frequency modifiers in PHA and LOPA are discussed, as well as the interrelationship of risk criteria and analysis boundaries. The course addresses how to document risk gaps in LOPA recommendations, including using LOPA to assign the target Safety Integrity Level (SIL) to identified Safety Instrumented Systems (SIS). Workshop examples are used to illustrate the methodology and emphasize key learning points.

Risk management

Risk criteria

Independent Protection Layers (IPL)

Core attributes

LOPA methodology

IPLs and side effects

Day 1:

Risk management

Process risk measurements

PHA workshop

Risk criteria

Hazardous and harmful events

Enabling conditions and conditional modifiers

LOPA criteria

Frequency workshop

Independent Protection Layers (IPL)

Types

Assessing independence

Independence workshop

Core attributes

Core attributes workshop

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2042 Layer of Protection Analysis (LOPA) (Cont.)

2-Day Course

Who Should Attend?

Process safety managers, process safety specialists, process engineers, operations personnel, instrumentation and electrical personnel, LOPA facilitation trainees, LOPA facilitators, and PHA facilitators .

1.4

CEUs

14

PDHs

Day 2:

LOPA methodology

Initiating cause frequency

IPL risk reduction

Independence of control and instrumented safety functions

LOPA IPL workshop

IPLs and side effects

Understanding secondary Consequences

Multiple LOPA workshop examples

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2052

1.4

CEUs

14

PDHs

Process Hazard Analysis Leadership Training

2-Day Course

Program Content:

This course is intended to prepare PHA team members for team leadership. It introduces techniques commonly utilized in the petrochemical, chemical, and oil and gas industries. It also includes hands-on example problems from industry.

Many engineers or operating company professionals have attended PHAs, but have not been prepared for the unique requirements of team leadership. This course, while providing an introduction to PHA methodologies, is intended to augment the skill sets of those persons. Each class offering is adjusted to meet the specific needs of the current class members, with class interaction encouraged.

Following introductions of class members, the course starts with a simple presentation on hazard and operability studies (HAZOP 101), and a hands-on example problem. Next, the team discusses the evolution of PSM in the United States so that team leaders understand how PSM came about.

Regulatory requirements for PHAs are then discussed, including Process Safety Management (PSM) programs, Risk Management Programs (RMP), and Safety and Environmental Management Systems (SEMS). Discussion includes when studies are required, and assists the PHA leader in identifying and managing compliance issues.

Along with discussion of the PHA methodologies, attendees discuss how to prepare for a PHA, and then how to manage the team during the project implementation. Preparation of reports is another topic, presented with visual examples. Additionally, checklists of general safety issues, facility siting issues, and human factor issues are included in the class notes.

Day 1:

Introductions

HAZOP 101 with workshop

Evolution of PSM

Regulatory requirements for PHAs

Preparation for PHAs

Leadership skills for managing teams

HAZOPs—in detail

HAZOP workshop

Day 2:

What-If? And What-If? / checklist

What-If? workshop

FMEA and fault tree analysis

PHA reports and documentation

Facility siting, human factors

LOPAs in PHAs

PHA software

PHAs for batch processes

PHAs for process modifications

Final workshop

Who Should Attend?

Process Hazard Analysis participants

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2073 Safety Instrumented Systems (SIS) Implementation

3-Day Course

Program Content:

This course reviews the various good engineering practices that apply to Safety Instrumented Systems (SIS) implemented in process industry facilities. It presents the requirements of IEC 61511 using a lifecycle framework that is supplemented with several industrial guidance documents. It explains how risk analysis techniques, such as Layer of Protection Analysis (LOPA), are used to identify the need for administrative and engineered safeguards. IEC 61511 establishes requirements for designing and managing SISs to achieve specified Safety Integrity Levels (SIL), which are related to order of magnitude ranges of risk reduction. When LOPA determines that an SIS is required, the required risk reduction becomes the target SIL for the SIS.

The course is designed to provide the student with an understanding of the required safety management system, how to perform LOPA to identify the need for an SIS and to assign the SIL, how to design the SIS to meet the specified SIL, how to verify that the SIL can be achieved, and how to develop an operating plan to maintain the SIL throughout the SIS life.

SIS standards overview Planning Process risk and protection layers Establishing risk evaluation criteria Layer of Protection Analysis (LOPA) Selection of devices Data estimation Design decisions Verification example Operating basis

Day 1: Getting Started

Module 1—SIS Standards Overview This course begins with a brief introduction to the various good engineering practices that apply to Safety Instrumented Systems (SISs) implemented in process industry facilities. Special focus is given to international standards, such as IEC 61511 and 61508, and recognized guidance documents, such as the CCPS Guidelines books and several ISA technical reports.

Module 2—Planning An overview of IEC 61511 is presented followed by detailed requirements for the safety management system contained in clauses 5 through 7. Key elements are competence, independent review, verification, functional assessment, management of change, and auditing.

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2073 Safety Instrumented Systems (SIS) Implementation

3-Day Course

Module 3—Process Risk and Protection Layers

Process risk derives from process miss-operation and is an inherent part of process design. This inherent risk must be reduced below internationally accepted risk criteria using Independent Protection Layers (IPLs) that are designed and managed to meet seven (7) core attributes.

Module 4—Establishing Risk Evaluation Criteria

The risk assessment phase is addressed in IEC 61511 Clauses 8 and 9. The initiating events for process hazards are identified, and the frequency and consequence severity of each potential event is estimated. Depending on the type of risk analysis, various conditional modifiers may also be considered when assessing the risk. Once the risk is understood, a risk reduction strategy can be developed.

Day 2: Risk Analysis to Design

Module 5—Layer of Protection Analysis Layer of protection analysis (LOPA) is covered in the CCPS book, Layer of Protection Analysis: Simplified Process Risk Assessment. LOPA identifies the initiating events and their frequency, the consequences and their severity, the required risk reduction, and the protective functions implemented in each protection layer to achieve the required risk reduction.

Module 6—Safety Requirements Specification (SRS) Part 1

The SRS in IEC 61511 Clause 10 is a collection of information that specifies the SIS design basis required to ensure process safety during all operating modes. The SRS defines the functionality, integrity, reliability, operability, and maintainability requirements based on operational goals, intended operating modes and process safety time limitations.

Module 7—Safety Requirements Specification Part 2

IEC 61511 Clause 11 provides many specific design requirements including the need for fault tolerance and separation of the SIS from the BPCS.

Module 8—Selection of Devices

SIS device selection is addressed in IEC 61511 Clause 11.5. ISA TR84.00.04 guidance is presented related to field devices and logic solvers. Emphasis is placed on demonstrating that the device is user-approved for safety based on a review of manufacturer information and actual field experience.

15

2073 Safety Instrumented Systems (SIS) Implementation

3-Day Course

Day 3: Verification and Operating Basis

Module 9—Data Estimation IEC 61511 Clause 11.9 requires verification of the SIS performance through calculation of the probability of failure on demand (PFD) and the spurious trip rate of the SIS as specified and maintained. Various types of data estimates are discussed with an emphasis on collecting internal and industrial data.

Module 10—Design Decisions

The voting architecture, diagnostic coverage, proof test interval, and common cause failure potential affects the achievable PFD, and the spurious trip rate. The impact of each design decision is discussed and typical examples are presented.

Module 11—Example Verification

An example of Safety Instrumented Functions (SIF) will be assessed to illustrate how choices in field device architecture, test interval, and logic solver technology affect the achievable PFD and spurious trip rate.

Module 12—Operating Basis

There are many day-to-day operational and maintenance activities that must take place for the SIS to sustain its expected performance throughout its installed life. Operation and maintenance procedures must be developed and verified prior to the introduction of hazards into the process unit. These procedures support the detection and response to faults and process alarms, the initiation of manual shutdown, reset after shutdown, and proof tests.

Who Should Attend?

Control systems, instrument, electrical, and process safety specialists, PSM managers, and PSM compliance auditors.

2.1

CEUs

21

PDHs

16

2082 Safety Integrity Level (SIL) Verification

2-Day Course

Program Content:

This course covers the performance verification of Safety Instrumented Functions (SIF), including calculation of the Probability of Failure on Demand (PFD) and Spurious Trip Rate (STR). These calculations must take into account the device failure rates, system architecture, subsystem voting configuration, specified diagnostics and testing, and repair times. The PFD calculation must also take into account the susceptibility of the SIF to common mode and common cause failure.

IEC 61511 requires that the PFD be verified by calculation to prove that each SIF meets its target Safety Integrity Level (SIL). This course provides students with an understanding of the fundamentals needed to address this requirement in their workplace. It familiarizes students with Failure Modes and Effects Analysis (FMEA), the identification of safe, dangerous, detected, and undetected device failures, the selection of failure rate data, understanding key design parameters, and applying the calculation methodology. The two approaches for approving a device for use in an SIS - certification and prior use - are also explained.

The course presents a series of examples as workshops to illustrate the important concepts and assumptions implicit in the calculations. The student must bring a scientific calculator and notepad to the course.

Overview of the requirements of SIS standards

Failure analysis fundamentals

Failure Modes and Effects Analysis (FMEA)

Introduction to the math for probability of failure on demand and spurious trip rate

Key elements affecting performance

Workshops -- problems worked by students. Various cases will be modeled showing how changes to design and maintenance strategy affect results.

Day 1:

Overview of SIS standards

Failure fundamentals—Failure Modes and Effects Analysis (FMEA)

Introduction to the math for probability of failure on demand and spurious trip rate

Key Elements

Integrity—Where do you get data from? What does it mean?

Voting/Fault Tolerance—why do you need redundancy? How does it help?

Test Interval—How does the test interval affect the integrity?

Diagnostic Coverage—What effect does diagnostics have?

Common Cause—How is this modeled?

17

2082

1.4

CEUs

14

PDHs

Safety Integrity Level (SIL) Verification

2-Day Course

Periodic workshops throughout the day

How to read manufacturer certification reports

How to model SIF based on LOPA recommendations

Understanding mean time to failure and useful life

Partial stroke testing and proof test coverage

Day 2:

Example System

Impact of diagnostics and need for compensation measures

Calculation demonstration showing the impact of redundancy

Workshops—problems worked by students. Various cases will be modeled showing how changes to design and maintenance strategy affect results.

Who Should Attend?

Control systems engineers, instrument engineers, and process safety specialists.

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Program Content:

The OSHA 1910.119 Process Safety Management (PSM) mandate of 1993 brought safety to the forefront of our businesses. Along with many other pieces of critical process safety information, it demanded adequate verification and documentation of the design basis for all new and existing pressure relief and disposal systems. However, it did not outline how to do this nor what constitute “adequate” documentation. Due to imposed deadlines that quickly approached, companies rushed to be in compliance. In the mid‐1990’s, most would argue that there was not enough time nor money budgeted to carry out the huge scope of work that OSHA 1910.119 called for. Consider for a moment the operations of one of the larger refineries (~300,000 BPD) in the United States and read the following questions:

How does this refinery identify, analyze, and maintain all of the equipment, relief device and process information associated with 5,000 pieces of equipment, 20,000 overpressure scenarios, and millions of flare venting combinations?

How does this refinery ensure that all pressure relief and disposal system information is accurate, accessible, and maintainable?

How does this refinery do all of the above without incurring astronomical costs? Approximately twenty years after the initial push for compliance and the implementation of the OSHA National Emphasis Program (NEP), companies have some breathing room to re‐ask themselves the above questions. The answers are the best practices covered in this course. The ultimate goal is a corporate‐wide standardization of philosophy, engineering analysis, software, and information management that guarantees an accurately designed, electronically documented, and easily maintained pressure relief and disposal system for an acceptable dollar investment. These best practices outline how to achieve this goal:

Adoption of a sensible approach to risk management

Commitment to best practices Standardization of equipment‐based engineering analysis

Identifying and implementing appropriate Recognized and Generally Accepted Good Engineering Practices (RAGAGEPs)

Standardization of relational database and integrated information management architecture

Coupling of pressure relief and disposal system documentation to Management of Change processes

Relief device inspection program

Relief device removal procedures

3102 Pressure Relief Systems—Best Practices

2-Day Course

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Pressure Relief Systems—Best Practices (Cont.)

2-Day Course

1.4

CEUs

14

PDHs

3102

Who Should Attend?

This course outlines the best practices of pressure relief design so it is primarily intended for personnel who have the responsibility of maintaining and auditing the pressure relief system design basis documentation for OSHA 1910.119 compliance. The intended audience includes auditors, process engineers, technical managers, and project managers.

20

Program Content:

As an introduction to reactivity of industrial chemicals and the evaluation of potential hazards due to their reactive nature, this course discusses identification and characterization of chemical hazards. Also discussed is the use of a hierarchical evaluation and management approach for safer and more economical chemical processes.

Why a systematic approach to chemical reactivity is important

Why reactive hazard management should include management of risk

Definition of a potentially hazardous reactivity

Types of chemicals and chemical reactions

Chemical incompatibility

Chemical energy of formation and potential release of energy

Effects of catalysis, inhibitors, contaminants, and corrosion products

Reaction conditions, including temperature, pressure, concentration, and time

Equipment reliability and availability including failure, testing, and repair

Systematic prediction of potential chemical hazards using literature information, computation methods, screen testing, and detailed experimental analysis

Industrial case studies illustrating effects of energy, reaction pathways, unexpected reactions, kinetics, and aging

Who Should Attend?

Reactive hazards analysts, process safety managers and coordinators, and operation managers and superintendents.

Note: This class is also available as a two-day class.

3111

0.7

CEUs

7

PDHs

Reactive Chemical Hazards Assessment

1-Day Course

21

3121

0.7

CEUs

7

PDHs

Reducing Human Error in Process Safety

1-Day Course

Program Content:

Human error is a significant source of risk within any organization. Management uses a variety of operational controls and barriers, including policies, procedures, work instructions, employ‐ee selection and training, auditing, etc., to reduce the likelihood of human error. Accidents oc‐cur when there is a failure in one or more of these controls and/or barriers.

Many companies are working to reduce their incident rates by integrating a more detailed analysis of human factors into their incident investigation procedures. In doing so, companies can identify weaknesses in their operational controls at a specific job site, within an operating region, and across the organization. Subsequent improvements to these controls will then help to reduce the on.

The following course will outline a process that companies can use to integrate human factor data into incident investigations and identify operational controls that need improvement. The course is being offered as either 1-day or 2-day training. The 1-day training will be open to representatives from different companies and will be more general in nature. The 2-day training will be provided to a single company and will be tailored to their specific operations.

Who Should Attend?

Process safety management coordinators, risk management planning coordinators, and new health, safety, and environment auditors.

22

Program Content:

The OSHA 1910.119 Process Safety Management (PSM) mandate of 1993 brought safety to the forefront of our businesses. Along with many other pieces of critical process safety information, it demanded adequate verification and documentation of the design basis for all safety disposal system components. However, it did not outline how to do this nor what constitute “adequate” documentation. Due to imposed deadlines that quickly approached, companies rushed to be in compliance.

The primary goal of a disposal system, such as flare, analysis is to ensure that all processes are adequately protected against potential global overpressure contingencies. The design basis of flare relief header system components such as pressure relief devices, piping network, knockout drums, flare seals, and flare tip should always be available and this data should reflect the current operating condition of the process.

In recent years, refining and petrochemical facilities have experienced tremendous growth in response to increasing demand for fuels and chemical precursors. At the same time higher expectations were established to be incompliance with corporate, local, and federal regulations. Under these circumstances it has become more challenging to keep an eye on the update and maintenance of the flare header adequacy analysis during fast paced engineering design and debottlenecking projects. The challenge stems from the time and cost requirements that are associated with such an effort.

This course describes a best practice to analyze disposal systems that will provides refining, petrochemical and chemical facilities operators and managers with comprehensive plan to efficiently maintain and reflect the adequacy status of the flare system components. The course outlines the following components:

Commitment to best practices and adoption of a sensible approach to risk management

Standardization of disposal systems analysis

Identifying and implementing appropriate Recognized and Generally Accepted Good Engineering Practices (RAGAGEPs)

Standardization of relational database and integrated information management architecture

Disposal system components engineering analysis

Flare quantitative risk analysis (QRA) and flare consolidation

Relief device inspection program Relief device removal procedures

Who Should Attend? This course outlines the best practices of pressure relief design so it is primarily intended for personnel who have the responsibility of maintaining and auditing the pressure relief system design basis documentation for OSHA 1910.119 compliance. The intended audience includes auditors, process engineers, technical manages, and project managers.

3151

0.7

CEUs

7

PDHs

Disposal Systems Analysis—Best Practices

1-Day Course

23

Program Content:

This course will discuss and exercise decision making examples using decision tree figures and other tools to analyze decision alternative outcomes and probabilities including the likelihood of observing particular outcomes in tests to lower uncertainty for more accurate decision making.

Course topics include:

Method and components of an engineering decision

‘Flaw of averages’ and the importance of working with variability of critical parameters

Use of probability to model uncertain events and guide uncertainty reduction

Expected likelihood and expected utility of alternative outcomes

Value of information and method to determine how much additional information, if any, is needed prior to making an engineering decision, and the value of perfect information to find the value limit of additional information to make a given decision

Bayes Model to update probability estimates using new information

How to calibrate engineering decisions based on tolerable risk ranges

Information gathering, analysis, and decision making are vital components of engineering responsibility. This responsibility includes the value of information to decrease uncertainty for cost effective decrease of outcome risk. Such decisions employ information to estimate values and outcome probabilities of decision alternatives. Therefore, the pillars of engineering decision making are the values and probabilities of alternative outcomes. Exercises and case studies drawn from life and from engineering applications will illustrate the tools needed for professional decision making applications. Case studies include natural gas or oil drilling, building extension and rebuilding, toxic exposures, dikes to avoid flooding, replacement of leaking pipeline, and offshore platforms.

Who Should Attend?

All engineering personnel (design, operations, maintenance) who are involved in day-to-day operations and decision making in the plants. In addition, all project managers should attend this course.

Note: This class is also available as a two-day class.

4061

0.7

CEUs

7

PDHs

Engineering Decision Making

1-Day Course

24

4072

1.4

CEUs

14

PDHs

Gas Explosion Hazards in Petrochemical Facilities:

Onshore/Offshore

2-Day Course

Program Content:

An advanced course looking into explosion hazards on offshore facilities. The course addresses all aspects of explosion hazards: ignition processes, release and dispersion, explosion mechanisms, blast loads and modeling of all these aspects. On the second day, a tour of the TEEX Brayton Fire Training Field and Disaster City. Course attendants will experience at least one large-scale fire demonstration.

Day 1:

Gas Explosion Basics

Explosion Accidents: Statistics and Examples

Rough Offshore Explosion and Investigation

Release and Dispersion in Offshore Facilities

Ignition Sources—Fundamentals

Preventative Measures

Mitigation and Control

Day 2:

North Sea—Lessons Learned

Advanced Explosion Modeling

Explosion Analyses

Part 1: Objective and Motivation

Part 2: Explosion Risk Analyses—Simple Approach

Part 3: Explosion Risk Analyses—Advanced Approach

Part 4: Selected Examples of Safety Case Analyses

Who Should Attend?

Safety engineers, safety consultants, structural & design engineers, oil & gas HSE, investigation team leaders, and process safety management coordinators.

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Fire protection design concepts and considerations for chemical, petrochemical, and hydrocarbon processing facilities. Special attention is given to fire hazard analysis, fire risk assessment, fire protection features, and emergency response. Specific fire protection design considerations are studied for the various types of facilities and processes. Prerequisite: Instructor approval.

Application of scientific and engineering principles in the selection and design of control systems related to chemical, physical, and ergonomic exposures in the process and manufacturing industries, relationships of criteria, analysis and specifications for the assessment and control of occupational related illnesses.

Concepts of designing, operating, and maintaining optimally safe systems, risk management, economic impact, legislation, performance measurement, and accident investigation and analysis, principles and practices in Industrial Hygiene Engineering, Fire Protection Engineering, and Introduction to Systems Safety Engineering.

COURSES OFFERED VIA DISTANCE LEARNING

Our Distance Learning Program allows individuals in a university academic program to participate in university courses. These courses follow the syllabus outline with all other students, completing homework, taking quizzes and exams, and projects as applicable. In order to receive a certificate for these courses, participants must complete all work and receive a ‘C’ or better on graded work. These courses follow the academic calendar and are offered on a semester basis (Fall: August—December; Spring: January—May).

SENG 422: Fire Protection Engineering

SENG 310: Industrial Hygiene Engineering

SENG 321: Industrial Safety Engineering

4.2

CEUs

42

PDHs

4.2

CEUs

42

PDHs

4.2

CEUs

42

PDHs

26

Concepts of risk and risk assessment, which uses all available information to provide a foundation for risk-informed and cost-effective engineering practices. Examples and exercises are drawn from a variety of engineering areas.

Application of system safety analytical techniques to the design process, emphasis on the management of a system safety or product safety program, relationship with other disciplines, such as reliability, maintainability, human factors, and product liability applications.

4.2

CEUs

42

PDHs

SENG 312: System Safety Engineering

4.2

CEUs

42

PDHs

Following the growth in complexity of engineering systems, demands are increasing for health, safety, and environmental quality with more stringent requirements for reliability and increased engineering performance. This course presents the fundamentals of quantitative risk analysis for cost-effective engineering applications, risk criteria, and risk decisions.

CHEN 460/660: Quantitative Risk Analysis in Safety Engineering

CHEN 430—SENG 430: Risk Analysis Safety Engineering

4.2

CEUs

42

PDHs

Applications of engineering principles to process safety and hazards analysis, mitigation, and prevention, with special emphasis on the chemical process industries, including source modeling for leakage rates, dispersion analysis, relief valve sizing, fire and explosion damage analysis, hazards identification, risk analysis, and accident investigations.

4.2

CEUs

42

PDHs

CHEN 455/655—SENG 455/655: Process Safety Engineering

27

REGISTRATION

Register Online:

To register online go to: http://psc.tamu.edu/education/continuing-education

When on the Schedule of Classes and Registration page, select from the list of courses offered and choose Register for this course. You will be linked to a secure site allowing you to register and pay for the course online. You will receive a confirmation email upon completing your reg‐istration.

Register by Phone:

Call 979-845-3489 and we will take your registration over the phone. Hours are 8 am to 5 pm, CST, Monday through Friday.

Register by Fax:

Fax your registration to 979-458-1493, 24 hours a day, 7 days a week.

Register by Mail:

Mary Kay O’Connor Process Safety Center

Attention: Valerie Green

Texas A&M University

3122 TAMU

College Station, TX 77843-3122

Make checks payable to: Mary Kay O’Connor Process Safety Center

For all other questions contact:

Valerie Green

Associate Director—Administration

Email: val-green@tamu.edu

28

Mary Kay O’Connor Process Safety Center

Continuing Education Registration Form

COURSE TITLE COURSE DATE FEE

CANCELLATION & REFUND POLICY

1) If the course is cancelled for any reason, we will provide a 100% refund or the student can transfer their

registration fee to the next offering of the same course, or to a different course.

2) If the student cannot attend the course, they may have a substitute attend.

3) Cancellations must be received ten working days prior to the start of the course to receive a refund. After

that time, there will be a 30% penalty. All refunds will incur a $25 service charge.

4) The Center will not be responsible for any costs and/or expenses incurred by the registrant when a class is

cancelled.

*Email addresses received via this registration form will be added to our email distribution list unless otherwise noted.

REGISTRATION & FEES

Early registration is 4 weeks prior to the course date.

See individual classes for fee (based on course

duration).

Please send registration form and check (made payable

to the Mary Kay O’Connor Process Safety Center) or

fax registration if paying by credit card (American

Express, Diners Club, MasterCard, or Visa) to:

Mary Kay O’Connor Process Safety Center

Attention: Valerie Green

Texas A&M University

College Station, TX 77843-3122

Phone: (979)845-6884

Fax: 979-458-1493

Last Name First Name MI

Company Name

Mailing Address

State Zip Code City

Telephone Fax Email Address*

Circle one:

Total $

Credit Card #: Exp. Date:

Card Holder: Security Code:

To register online go to http://psc.tamu.edu/education/continuing-education and select courses offered under

the Standard Courses section and then you will be linked to the website listing all of our courses. Follow the

instructions and be sure to wait for confirmation that your registration was received before exiting the site.

29

Mary Kay O’Connor Process Safety Center

http://psc.tamu.edu